infinite build volume printer

Many different projects started with the same thought: “That’s really expensive… I wonder if I could build my own for less.” Success is rewarded with satisfaction on top of the money saved, but true hacker heroes share their work so that others can build their own as well. We are happy to recognize such generosity with the Hackaday Prize [Robinhood] achievement.

Achievements are a new addition to our Hackaday Prize, running in parallel with our existing judging and rewards process. Achievements are a way for us to shower recognition and fame upon creators who demonstrate what we appreciate from our community.

Fortunately there is no requirement to steal from the rich to unlock our [Robinhood] achievement, it’s enough to give away fruits of price-reduction labor. And unlocking an achievement does not affect a project’s standings in the challenges, so some of these creators will still collect coveted awards. The list of projects that have unlocked the [Robinhood] achievement will continue to grow as the Hackaday Prize progresses, check back regularly to see the latest additions!

In the meantime, let’s look at a few notable examples that have already made the list:

3D printers can be used in a manufacturing context. This might be surprising for anyone who has waited hours for their low-poly Pokemon print, but for low-volume plastic parts, you can actually run a manufacturing line off a few 3D printers. The problem with 3D printers is peeling the print off when it’s finished. If only there were a conveyor belt solution for a bed that wasn’t forgotten by MakerBot.

[Swaleh] may have a solution to the problem of un-automated 3D printers. He’s designing the WorkHorse 3D, a printer that uses a conveyor belt as a bed. When the print is finished, the conveyor belt rolls forward, depositing a printed part in a bin. It’s the solution to truly automated printing.

The use of conveyor belts to automate a batch of 3D prints isn’t a new idea. Way back in the Before Time, MakerBot released the Automated Build Platform, and used it in production to print off parts for Thing-O-Matics. This bit of Open Hardware was left by the wayside for some reason, and last year saw the invention of a new type of conveyor belt-based printer, The Infinite Build Volume Printer (for lack of a better name) from [Bill Steele]. This printer angles the print bed at 45 degrees, theoretically allowing for prints that are infinitely long. This idea was turned into the Printrbot Printrbelt, and the Blackbelt 3D printer was made public around the same time.

[Swaleh]’s printer is not of the infinite build volume variety. Instead of concentrating on creating long beams, most of the engineering work has gone into making a printer that’s designed to just push prints out. The conveyor belt bed is flat — and may unfortunately infringe on the MakerBot patents — but if you want a printer that’s designed to dump parts out like a very slow injection molding machine, this is the design you want.

The print queue application for this project is just a simple desktop app that serves as a buffer for G-code files. The app sends one G-code file off to the printer, rolls the bed forward, and queues up the next part. It’s simple, yes, but there aren’t too many things that do this now because there aren’t too many printers built to be factories. It’s impressive, and you can check out a few videos of this printer in action below.

One of the most interesting developments in 3D printing in recent memory is the infinite build volume printer. Instead of a static bed, this type of printer uses a conveyor belt and a hotend set at an angle to produce parts that can be infinitely long in one axis, provided you have the plastic and electricity. For this year’s Hackaday Prize, [inven2main] is exploring the infinite build volume design, but putting a new spin on it. This is a printer with a conveyor belt and a SCARA arm. The goal of this project is to build a printer with a small footprint, huge build volume, no expensive rails or frames, and a low part count. It is the most capable 3D printer you can imagine using a minimal amount of parts.

Most of the documentation for this build is hanging around on the RepRap forums, but the bulk of the work is already done. The first half of this build — the SCARA arm — is well-traveled territory for the RepRap community, and where there’s some fancy math and kinematics going on, there’s nothing too far out of the ordinary. The real trick here is combining a SCARA arm with a conveyor belt to give the project an infinite build volume. The proof of concept works, using a conveyor belt manufactured out of blue painter’s tape. These conveyor belt printers are new, and the bed technology isn’t quite there, but improvements are sure to come. Improvements will also be found in putting a small crown on the rollers to keep the belt centered.

All the files for this printer are available on the Gits, and there are already a few videos of this printer working. You can check those out here.

The last three days marked the 2018 Midwest RepRap Festival. Every year, the stars of the 3D printing world make it out to Goshen, Indiana for the greatest gathering of 3D printers and printing enthusiasts the world has ever seen. This isn’t like any other 3D printing convention — everyone here needs to take the time to get to Goshen, and that means only the people who want to be here make it out.

Over the weekend we covered some amazing hacks and printer builds from MRRF. The ‘BeagleBone On A Chip’ has become a complete solution for a 3D printer controller. This is a great development that takes advantage of the very under-used Programmable Real-Time Units found in the BeagleBone, and will make an excellent controller for that custom printer you’ve been wanting to build. E3D has announced they’re working on an automatic tool-changing printer. It’s a slight derivative of their now-defunct BigBox printer, but is quite possibly the best answer to multi-material filament printers we’ve ever seen. There’s some interest from the community, and if everything goes well, this printer may become a kit, or something of the sort. Filament splicing robots also made an appearance at this year’s MRRF, and the results are extremely impressive. Now you can create multi-color prints with the printer you already own. Is it expensive? Yes, but it looks so good.

This wasn’t all that could be found at MRRF. There were hundreds of printers at the event, and at last count, over 1300 attendees. That’s amazing for a 3D printer convention that is held every year in the middle of nowhere, Indiana. What were the coolest sights and sounds coming out of MRRF this year? Check out the best-of list below.

We’ve seen 3D printers coming out with infinite build volumes, including some attempts at patenting that may or may not stall their development. One way around the controversy is to do it in a completely different way. [Aad van der Geest]’s solution may not give you the ability to print an infinitely long part, but it will allow you to print an infinite number of the same, or different, parts, at least until your spool runs out.

One of many things that we think is pretty clever, as well as fun to watch, is that after the part is finished, the extruder moves to the top corner of the printer and presses a micro switch to tell the PIC12F629 to start the part removal process. You can see this in the first video below. The G-code takes over again after a configurable pause.

But [Aad]’s put in more features than just that. As the second video below shows, after the parts have been scraped from the build plate, a pin on the extruder is used to lift and drop the blade a few times to remove small parts that tend to stay on the blade. Also, the extruder is purged between prints by being moved over a small ridge a few times. This of course is also in that special G-code.

How do you produce the special G-code, since obviously it also has to include the parts to print? For that [Aad]’s written a Windows program called gcmerge. It reads a configuration file, which you edit, that contains: a list of files containing the G-code for your parts, how many to print, whether or not you want the extruder to be purged between prints, various extruder temperatures, cooling times, and so on. You can find all this, as well as source for the gcmerge program, packaged up on a hackaday.io page. Incidentally, you can find the PIC12F629 code there too.

[Brook Drumm] of Printrbot is teasing a new 3D printer. This is no ordinary 3D printer; this is an infinite build volume 3D printer, the Next Big Thing™ in desktop fabrication.

The world was introduced to the infinite build volume 3D printer last March at the Midwest RepRap Festival with a built by [Bill Steele] from Polar 3D. The design of [Bill]’s printer began as simply a middle finger to MakerBot’s Automated Build Platform patent. This was patent engineering — [Bill] noticed the MakerBot patent didn’t cover build plates that weren’t offset to the plane of the print head, and it just so happened a printer with a tilted bed could also build infinitely long plastic parts.

While [Bill Steele]’s unnamed printer introduced the idea of an infinite build volume printer to the community, a few pieces of prior art popped up in the weeks and months after MRRF. Several years ago, [Andreas Bastian] developed the Lum Printer, an unbounded conveyor belt printer. A month after MRRF, Blackbelt 3D introduced their mega-scale tilted bed printer and later started a Kickstarter that has already reached $100,000 in pledges.

Right now, details are sparse on the Printrbelt, but there are a few educated guesses we can make. The belt of the Printrbelt appears to be Kapton film attached to some sort of substrate. The hotend and extruder are standard Printrbot accouterments, and the conveyor is powered by a geared stepper motor. All in all, pretty much what you would expect.

We do know that [Brook] and [Bill Steele] are working together on this printer, apparently with [Brook] in charge of the hardware and [Bill] taking either his slicing algorithm or firmware modifications (we’re not exactly sure where the ’tilt’ in the Gcode comes from) and getting this printer running.

While the Printrbelt isn’t ready for production quite yet, this is a fantastic advance in the state of consumer, desktop 3D printing. You can check out [Brook]’s teaser videos below.

Very rarely do we see a 3D printer that is more than just a refinement of what’s currently standard practice. [Prusa]’s single-hotend, four-color printer makes the list, but that came out a while ago. The novel 32-bit controller board found in last year’s $200 Monoprice printer has the potential to change a cottage industry. Save those two exceptions, innovation in 3D printing really isn’t seeing the same gains we saw in 2010 or 2011.

A company out of the Netherlands, Blackbelt 3D, is bringing out the most innovative 3D printer we’ve seen since last March. It’s an infinite volume 3D printer that’s built for autonomous production. This printer can produce row after row of 3D printed parts, or it can print an object longer than the build plate. If you have enough time, filament, and electricity, there’s no reason you couldn’t print a plastic beam hundreds of meters long.

The specs on this printer are about what you would expect from a large machine meant for industry or prototyping, as opposed to a machine designed to print out tugboats and fidget spinners. The Blackbelt uses interchangeable print heads for the hotend with 0.4, 0.6 or 0.8 mm nozzles. The filament feed is a Bowden with the extruder hidden under the control panel. The frame is explicitly Bosch extrusion, and the machine’s build volume is 340 mm by 340 mm by whatever. Retail price (on Kickstarter) comes in at €9,500, but for an extra €3,000 you can also get a neat stand with casters on the bottom. Of course, with an infinite build volume, you could also print a stand. Continue reading “Another Printer With An Infinite Build Volume”→